Cooling member, manufacturing method and apparatus thereof

ABSTRACT

A cooling member includes a heat-transfer member having a groove and a refrigerant introducing pipe pressed into the groove. The refrigerant introducing pipe has a pressed region positioned inwardly of the edge of the heat-transfer member, and at least one curbed surface portion. A method for manufacturing a cooling member includes preparing a punch having at least one curved corner and a pressing surface, positioning the corner, and moving the punch closer to the groove to press the refrigerant introducing pipe into the groove with the pressing surface. A device for manufacturing a cooling member includes the punch and a support configured to support the heat-transfer member so the groove is positioned opposite the punch.

FIELD OF THE INVENTION

The present invention relates to a cooling member formed by pressing arefrigerant introducing pipe into a groove of a heat-transfer member anda method and a device for manufacturing the same.

DESCRIPTION OF THE RELATED ART

FIG. 19 shows a cooling member 607 formed by pressing a refrigerantintroducing pipe 605 into a groove 603 of a heat-transfer member 601 anda punch 613 in which a pressing surface 611 is provided between twocorners 609. The heat-transfer member 601 is an aluminum plate. Thelimit of a longitudinal direction in the groove 603 coincides with edges615 of both sides of the heat-transfer member 601. The refrigerantintroducing pipe 605 is a steel pipe. The cooling member 607 isassembled by the procedures mentioned below.

As shown in FIG. 20 (a), the corners 609 of the punch 613 are positionedright above the edges 615 of the heat-transfer member 601 and therefrigerant introducing pipe 605 is inserted into the groove 603. Atthis point, as shown in FIG. 20 (b), there is a clearance between aninner surface of the groove 603 and the refrigerant introducing pipe605. Subsequently, the punch 613 is moved forward (fall) toward thegroove 603 to press the pressing surface 611 of the punch 613 to therefrigerant introducing pipe 605. Thereby, as shown in FIGS. 20( c) and20(d), the refrigerant introducing pipe 605 is plastically deformed anda joint between the heat-transfer member 601 and the refrigerantintroducing pipe 605 at a place where the refrigerant introducing pipe605 is closely fitted with the inner surface of the groove 603 iscompleted.

However, when the refrigerant introducing pipe 605 is pressed by thepunch 13, scars 617 caused by the corners 609 remain on a surface of therefrigerant introducing pipe 605, resulting in damage in reliability ofthe refrigerant introducing pipe 605. When an external force is appliedto the refrigerant introducing pipe 605 in a bending direction after theheat-transfer member 604 and the refrigerant introducing pipe 605 arejoined, its stress focuses near a boundary between the refrigerantintroducing pipe 605 and the edges 615, resulting in reduction inphysical strength of the refrigerant introducing pipe 605. Although itis possible to avoid the focus of the aforementioned stress byperforming R processing at the rim of the groove 603 so that clearancebetween the inner surface of the groove 603 and the refrigerantintroducing pipe 605 may be formed near the edges 615, an extraprocessing expense for the processing is needed.

A reaction force created when the refrigerant introducing pipe 605 ispressed by the punch 613 allows the refrigerant introducing pipe 605 tobend toward the opposite side of the corners 609. This causes errors indimension and direction of the refrigerant introducing pipe 605projected from the edges 615 of the heat-transfer member 601. θ in FIG.20( c) indicates an angle at which the refrigerant introducing pipe 605is bent by the aforementioned reaction force.

Further, in the case where the refrigerant introducing pipe 605 isprotected with a coating material after the assembling of the coolingmember 607, the coating material is applied on a surface 619 of theheat-transfer member 601 and the refrigerant introducing pipe 605 andthe coating material is further applied to the boundary between therefrigerant introducing pipe 605 projected from the edges 615 and theedges 615. The latter work is so troublesome that care should be takento continue applying the coating material in the whole circumference ofthe refrigerant introducing pipe 605. In addition to that, technologiesto fit metal pipes or the like into grooves are disclosed in JP2007-218439 A, JP 2005-90794 A, and JP 10-79586 A.

In order to cool electric parts for producing heat such as powermodules, it is designed that a refrigerant introducing pipe made ofcopper to which a refrigerant is introduced is inserted into a grooveformed in an aluminum cooling member to make the cooling member incontact with the aforementioned electric parts. In this case, therefrigerant introducing pipe inserted into the groove of the coolingmember is plastically deformed so as to be closely fitted with thegroove of the cooling member with a press machine or the like, so thatthe refrigerant introducing pipe and the cooling member are joined.

However, when the refrigerant introducing pipe and the cooling memberbuild up condensation at the time of cooling at lower temperatures thanthe atmosphere, corrosion of the refrigerant introducing pipe and thecooling member caused by moisture which gets into a joint (boundary)between the refrigerant introducing pipe and the cooling member becomesa problem. The aforementioned problem becomes prominent when poisonousgas which deteriorates metals is contained in the atmosphere or whenpoisonous gas or salt is dissolved in a dew condensation water under anenvironment of the splash of salt. Further, in accordance with theprogress of corrosion of the refrigerant introducing pipe and thecooling member, thermal resistance of the joint is increased, whichleads to prevent the electric parts from being cooled. This deterioratesperformance of the electric parts. Technologies related to a jointbetween a refrigerant introducing pipe and a cooling member aredisclosed in JP 58-106395 A.

Moreover, technologies for bonding a pipe or the like to a groove of aheat-transfer member are disclosed in JP 2007-218439 A, JP 2005-90794 A,and JP 10-79586 A. As shown in FIG. 21 (a), when manufacturing a coolingmember formed by pressing a refrigerant introducing pipe into a grooveof a heat-transfer member, a refrigerant

introducing pipe 709 enters a groove 707 where an opening 705 is openedon a surface 703 of a heat-transfer member 701. Subsequently, therefrigerant introducing pipe 709 is pressed into the groove 707 with apunch 711 to plastically deform the refrigerant introducing pipe 709 soas to be closely fitted with an inner circumferential surface 713 of thegroove 707 as shown in FIG. 21 (b). This makes it possible to enlargethe width of the refrigerant introducing pipe 709 greater than a width Aof the opening 705 to join the heat-transfer member 701 to therefrigerant introducing pipe 709.

The inner circumferential surface 713 of the opening 705 is in such ashape that the cross section in a width direction thereof issubstantially arc-shaped. For instance, an external force in a deviationdirection may be applied to the refrigerant introducing pipe 709. Whenthe magnitude of this external force exceeds a friction force betweenthe heat-transfer member 701 and the inner circumferential surface 713,such defects that the refrigerant introducing pipe 709 rotates relativeto the heat-transfer member 701 occur. There is a limit to increase theaforementioned frictional force by simply increasing a force to pressthe refrigerant introducing pipe 709 with the punch 711.

It is preferable to increase an over hang quantity obtained by deducingthe difference between the width A of the opening 705 and a full width Bof the inner circumferential surface 713 to strengthen the join betweenthe heat-transfer member 701 and the refrigerant introducing pipe 709 sothat the refrigerant introducing pipe 709 plastically deformed asmentioned above may not be peeled off from the groove 707 of theheat-transfer member 701. However, to insert the refrigerant introducingpipe 709 into the groove 707 after passing through the opening 705, thewidth A of the opening 705 is needed to be greater than the diameter φof the refrigerant introducing pipe 709. Accordingly, it is difficult towiden the difference between the width A and the full width B and theover hang quantity is limited. This causes a problem that it isimpossible to strengthen the join between the heat-transfer member 701and the refrigerant introducing pipe 709.

As shown in FIG. 22 (a), a refrigerant introducing pipe 809 withdiameter φ is inserted into a groove 807 where an opening 805 is openedon a surface 803 of a heat-transfer member 801 to press the refrigerantintroducing pipe 809 into the groove 807 with a punch 811. This deformsthe refrigerant introducing pipe 809 plastically so that the refrigerantintroducing pipe 809 may be closely fitted with an inner circumferentialsurface of the groove 807 as shown in FIG. 22 (b).

Since an outer circumference (πφ) of the refrigerant introducing pipe809 and the circumference L of the groove 807 respectively includedimension errors, as shown in FIG. 22 (c), there is a possibility thatthe refrigerant introducing pipe 809 is not closely fitted with theinner circumferential surface of the groove 807. AS a result, aclearance may remain between the refrigerant introducing pipe 809 andthe groove 807. In this case, heat transfer from the heat-transfermember 801 to the refrigerant introducing pipe 809 is interfered.Further, when an external force is applied to the refrigerantintroducing pipe 809 in a twisted direction, the refrigerant introducingpipe 809 has a problem with rotation relative to the heat-transfermember 801. Alternatively, as shown in FIG. 22 (d), the refrigerantintroducing pipe 809 forcibly pressed into the groove 807 may be bent ina concave shape. In this case, the cross-section area of the innerrefrigerant introducing pipe 809 is becoming smaller, which results ininterference of a flow of a refrigerant to be introduced to therefrigerant introducing pipe 809.

However, it is difficult to manage dimensions of the heat-transfermember 801 and the refrigerant introducing pipe 809 in an integratedfashion because the two respectively have a different manufacturingprocess, thereby it is inevitable to make the quality of the coolingmember unstable.

SUMMARY OF THE INVENTION Problems to be Solved by the Invention

It is an object of the present invention to provide a cooling member toprevent a corner of a punch from being excessively pressed to a surfaceof a refrigerant introducing pipe and free from deterioration inreliability and physical strength and a method and a device formanufacturing thereof. Moreover, It is another object of the presentinvention to provide a cooling member which is capable of finishingdimensions of the refrigerant introducing pipe that projects from theheat-transfer member and the direction thereof with high precision, amethod and a device for manufacturing thereof.

It is still another object of the present invention to provide a coolingmember which is capable of avoiding corrosion of a refrigerantintroducing pipe and a heat-transfer member and maintaining heattransfer between the refrigerant introducing pipe and the heat-transfermember in good condition.

It is a further object of the present invention to provide a coolingmember in which a heat-transfer member and a refrigerant introducingpipe are firmly joined and a method for manufacturing thereof.

It is a still further object of the present invention to provide acooling member which is capable of performing good heat transfer from aheat-transfer member to a refrigerant introducing pipe and securing agood flow of a refrigerant to be introduced into the refrigerantintroducing pipe, and a method for manufacturing thereof. It is anotherobject of the present invention to provide a cooling member which iscapable of firmly holding the refrigerant introducing pipe on theheat-transfer member relative to an external force in a twisteddirection applied to the refrigerant introducing tube, and a method formanufacturing thereof.

Means for Solving the Problems

In a first preferred embodiment, to attain the aforementioned objects, amethod for manufacturing a cooling member according to the presentinvention configured to form a groove in a heat-transfer member havingat least one edge which is a longitudinal limit of the groove and pressa refrigerant introducing pipe into the groove, which comprises thesteps of: preparing a punch having at least one corner formed in acurved surface shape at one end or more and a pressing surface adjacentto the corner to arrange the pressing surface of the punch at a positionopposite to the groove; positioning the corner of the punch inwardly ofthe edge longitudinally located in the heat-transfer member; and movingthe punch closer to the groove to press the refrigerant introducing pipeinto the groove with the pressing surface.

In a second preferred embodiment of a cooling member according to thepresent invention configured to form a groove in a heat-transfer memberhaving at least one edge which is a longitudinal limit of the groove andpress a refrigerant introducing pipe into the groove with a pressmachine, a region to be pressed, which shrinks by being pressed with thepress machine is provided in the refrigerant introducing pipe, ispositioned inwardly of the edge longitudinally located in theheat-transfer member and at least one curbed surface portion in theshape of gradually shrinking in a direction where the refrigerantintroducing pipe is pressed to the press machine with a move from theedge of the heat-transfer member to the region to be pressed.

In a third preferred embodiment, a device for manufacturing a coolingmember according to the present invention configured to form a groove ina heat-transfer member having at least one edge which is a longitudinallimit of the groove and press a refrigerant introducing pipe into thegroove, the device comprises: a punch having at least one corner formedin a curbed surface shape at one end or more and a pressing surfaceadjacent to the corner; and a support for supporting the heat-transfermember in such a posture that the groove is arranged at a positionopposite to the pressing surface, wherein the corner contacts therefrigerant introducing pipe inwardly of the edge longitudinally locatedin a process in which the punch presses the refrigerant introducing pipeinto the groove with the pressing surface.

In a fourth embodiment of a device for manufacturing a cooling memberaccording to the present invention, at least one back-up portionextending outwardly of the edge longitudinally located in theheat-transfer member is provided on the punch and the back-up portionhits against the refrigerant introducing pipe when the corner of thepunch comes into contact with the refrigerant introducing pipe.

In a fifth preferred embodiment of a cooling member according to thepresent invention, the heat-transfer member has a surface where thegroove is opened and the surface of the heat-transfer member and therefrigerant introducing pipe are coated with a covering material.

In a sixth preferred embodiment of a cooling member according to thepresent invention, the covering material is a coating material to beapplied to the heat-transfer member and the refrigerant introducingpipe.

In a seventh preferred embodiment of a cooling member according to thepresent invention, the covering material is a cover for covering theheat-transfer member.

In an eighth preferred embodiment of a cooling member according to thepresent invention, electric parts are mounted on one surface and aheat-conducting member for making the heat-transfer member and therefrigerant introducing pipe closely fitted with each other is providedon the other surface.

In a ninth preferred embodiment of a cooling member according to thepresent invention, a sealing member for intervening between the grooveof the heat-transfer member and the refrigerant introducing pipe isprovided outwardly of the end longitudinally located in the region to bepressed.

In a tenth preferred embodiment of a cooling member according to thepresent invention, the groove has an inner circumferential surface in anoval shape to determine a center inwardly of the opening opened to asurface of the heat-transfer member and conform a direction of a majoraxis to a width direction of the opening and the refrigerant introducingpipe comprises: a curved portion being closely fitted with the innercircumferential surface; and a plane portion for blocking the opening.And in the cooling member according to the present invention, the ovalis an ellipse.

In an eleventh preferred embodiment, a method for manufacturing acooling member according to the present invention comprises the stepsof: preparing a punch having at least one corner formed in a curvedsurface shape at one end or more and a pressing surface adjacent to thecorner; preparing a heat-transfer member having a groove which has aninner circumferential surface in an oval shape to determine a centerinwardly of the opening and conform a direction of a major axis to awidth direction of the opening; inserting a refrigerant introducing pipeinto the groove to arrange a pressing surface of the punch at a positionopposite to the groove; positioning the corner of the punch inwardly ofat least one edge longitudinally located in the heat-transfer member;moving the punch closer to the groove to press the refrigerantintroducing pipe into the groove with the pressing surface; andplastically deforming the refrigerant introducing pipe so as to beclosely fitted with the inner circumferential surface of the groove. Andin the cooling member according to the present invention, the oval is anellipse.

In a twelfth preferred embodiment of the cooling member according to thepresent invention, a center of curvature of the inner circumferentialsurface in the groove is determined inwardly of the opening and a lengthobtained by adding the circumference of the inner circumferentialsurface to the width of the opening is shorter than an outercircumference of the refrigerant introducing pipe and the refrigerantintroducing pipe comprises: a curbed portion being closely fitted withthe inner circumferential surface; and a plane portion for blocking theopening and projecting from the surface.

In a thirteenth preferred embodiment of a method for manufacturing acooling member according to the present invention, the method comprisesthe steps of: preparing a punch having at least one corner formed in acurved surface shape at one end or more and a pressing surface adjacentto the corner; preparing a heat-transfer member having a groove whereina center of curvature of an inner circumferential surface is determinedinwardly of an opening and a length obtained by adding the circumferenceof the inner circumferential surface to the width of the opening isshorter than an outer circumference of the refrigerant introducing pipe;inserting a refrigerant introducing pipe into the groove to arrange apressing surface of the punch at a position opposite to the groove;positioning the corner of the punch inwardly of at least one edgelongitudinally located in the heat-transfer member; moving the punchcloser to the groove with the pressing surface; and plasticallydeforming the refrigerant introducing pipe so as to be closely fittedwith the inner circumferential surface of the groove.

Advantages of the Invention

According to a method for manufacturing a cooling member of the presentinvention, although the entire area of a pressing surface of a punchcomes in contact with a refrigerant introducing pipe substantially atthe same time in a process for moving the punch closer to a groove of aheat-transfer member, at least one corner of the punch gradually comesin contact with a surface of the refrigerant introducing pipe as therefrigerant introducing pipe is pressed to a pressing surface to beplastically deformed because the corner is formed in a curved surfaceshape at one end or more of the punch. Since this makes it possible todisperse a force in which the corner of the punch presses therefrigerant introducing pipe, it is possible to keep the surface of therefrigerant introducing pipe smooth and secure reliability and physicalstrength of the refrigerant introducing pipe.

In addition, a reaction force for plastically deforming the refrigerantintroducing pipe is completely received by the heat-transfer memberbecause the punch is such positioned that the corner of the punch can bepositioned inwardly of at least one edge longitudinally located in theheat-transfer member. Therefore, according to the method formanufacturing a cooling member of the present invention, an unnecessarybending force is not applied to the refrigerant introducing pipeprojecting from the edge of the heat-transfer member, which leads toassemble a cooling member that is accurate in dimension and direction ofthe refrigerant introducing pipe projected from the edge of theheat-transfer member.

In a device for manufacturing a cooling member of the present invention,back-up portions hit against the refrigerant introducing pipe in aprocess wherein the punch presses the refrigerant introducing pipe intothe groove with a pressing surface of the punch because the back-upportions extend from both ends of the punch. This makes it possible torestrict the refrigerant introducing pipe to upwardly warp by a reactionforce of the plastic deformation caused by a press machine of therefrigerant introducing pipe and assemble the cooling member that isaccurate in dimension and direction of the refrigerant introducing pipeprojecting from the edge of the heat-transfer member.

In the cooling member of the present invention, a region to be pressedis formed in the refrigerant introducing pipe by the shrinkage of therefrigerant introducing pipe in a direction of being pressed by a pressmachine. This region to be pressed is positioned inwardly of at leastone edge longitudinally located in the heat-transfer member. Further, acurbed surface portion in the shape of gradually shrinking in adirection being pressed by the press machine with a move from the edgeof the heat-transfer member to the region to be pressed. Accordingly,even when an external force is applied to the refrigerant introducingpipe in a bending direction, it is possible to disperse stress relativeto the external force to curved surface portions. This makes it possibleto secure physical strength of the refrigerant introducing pipe.

Moreover, in the cooling member assembled by a method for manufacturingthe cooling member of the present invention, a clearance between aninner surface of the groove in the heat-transfer member and therefrigerant introducing pipe remains near the edge of the heat-transfermember. Accordingly, even when an external force is applied to therefrigerant introducing pipe in the bending direction, it is possible toavoid the concentration of stress relative to the external force near aboundary between the refrigerant introducing pipe and the edge of theheat-transfer member. As a result, it is possible to reduce time and anexpense for carrying out R processing on each heat-transfer member whichwas conventionally needed.

For instance, it is possible to easily perform coating work of applyinga coating material to the refrigerant introducing pipe by introducingthe coating material into the whole circumference of the refrigerantintroducing pipe utilizing a capillarity phenomenon in which the coatingmaterial is drawn into the aforementioned clearance. Further, this workcan be done from a surface side of the cooling member and thus it ispossible to efficiently apply the coating material to a desired locationof the cooling member. It is also possible to perform the aforementionedmethod by the device for manufacturing the cooling member of the presentinvention.

In the cooling member of the present invention, the heat-transfer memberand the refrigerant introducing pipe inserted into a groove of theheat-transfer member are coated with a covering material to block thesurrounding atmosphere from a joint between the heat-transfer member andthe refrigerant introducing pipe. Accordingly, even when theheat-transfer member and the refrigerant introducing pipe build upcondensation, it is possible to prevent moisture from entering thejoint. It is also possible to prevent the heat-transfer member and therefrigerant introducing pipe from corrosion even when the heat-transfermember and the refrigerant introducing pipe contact poisonous gas or arein an environment in which salt is splashed. In addition, the coolingmember is capable of securing preferable heat transfer between theheat-transfer member and the refrigerant introducing pipe and promotingcooling of electric parts. As a result, it is possible to enable theelectric parts to exert its performance properly.

In the case where the covering material of the cooling member of thepresent invention is a coating material, the application of the coatingmaterial to the heat-transfer member and the refrigerant introducingpipe alone makes it possible to easily attain the aforementionedadvantage. Alternatively, in the case where the covering material is acover for covering the heat-transfer member, there is an advantage thatthere is a low possibility of the covering material being damaged by anexternal force or an impact because physical strength of the coveringmaterial is higher than the aforementioned coating material.

For instance, the electric parts and the heat-transfer member may beconnected to each other through a heat-conducting member. In this case,it is possible to utilize the heat-conducting member as a coveringmaterial when the electric parts are mounted on one surface of theheat-conducting member and the heat-transfer member is closely fittedwith the refrigerant introducing pipe on the other surface of theheat-conducting member. This eliminates the use of the aforementionedcoating material or the aforementioned cover, so that the number ofcorrosion preventive structured parts is reduced, resulting in reductionin manufacturing costs.

In the case where a sealing member is inserted into the aforementionedclearance remained between an inner surface of the groove of theheat-transfer member and the refrigerant introducing pipe, it ispossible to prevent from the entering of water or dust and the likebetween the heat-transfer member and the refrigerant introducing pipe.

According to a method for manufacturing the cooling member of thepresent invention, it is possible to plastically deform the refrigerantintroducing pipe so as to be closely fitted with an innercircumferential surface of the groove by inserting the refrigerantintroducing pipe into the groove of the heat-transfer member andpressing the refrigerant introducing pipe into the groove by the punch.Further, the inner circumferential surface of the groove is in an ovalshape in which a center is determined inwardly of the opening.Accordingly, it is possible for the cooling member manufactured by themethod mentioned herein to prevent the refrigerant introducing pipe fromrotating relative to the heat-transfer member free from heavy dependenceon a frictional force between the heat-transfer member and the innercircumferential surface, even when an external force in a deviationdirection is applied to the refrigerant introducing pipe that is closelyfitted with the inner circumferential surface of the groove.

Additionally, in the cooling member of the present invention, thedimension difference between a major axis of the oval and the width ofthe groove becomes larger than the case where the cross section of theinner circumferential surface is in a conventional arc shape because thedirection of the major axis in the aforementioned oval coincides withthe width direction of the groove. In the process of forming a groove inthe cooling member, that is advantageous to increase an over hangquantity and thus it is possible to strengthen the join between theheat-transfer member and the refrigerant introducing pipe. Particularly,in the case where the aforementioned oval is an ellipse, there is anadvantage that it is possible to quantitatively determine the over hangquantity in the procedures that will be described later.

Moreover, the cooling member of the present invention is manufactured inthe method as below. That is, the refrigerant introducing pipe isinserted into the groove of the heat-transfer member to press therefrigerant introducing pipe into the groove with a punch. Therefrigerant introducing pipe partially projects from the opening of thegroove at the point when the refrigerant introducing pipe to beplastically deformed is closely fitted with the inner circumferentialsurface of the groove. Simultaneously, the full width of the refrigerantintroducing pipe becomes greater than the opening, resulting in thecompletion of the joint between the heat-transfer member and therefrigerant introducing pipe.

Thus, according to the manufacturing method for the cooling member ofthe present invention, there is no possibility of a clearance remainingbetween the heat-transfer member and the refrigerant introducing pipe atthe point when the heat-transfer member is joined to the refrigerantintroducing pipe, even when an dimensional error is respectivelyincluded in the outer circumference of the refrigerant introducing pipeand the circumference of the inner circumferential surface in thegroove. This makes the cooling member manufactured by the manufacturingmethod of the present invention possible to materialize preferableheat-transfer from the heat-transfer member to the curved portion of therefrigerant introducing pipe.

In the cooling member of the present invention, it is possible toprevent the refrigerant introducing pipe from being bent by force bysetting a force to press the refrigerant introducing pipe with the punchuntil the refrigerant introducing pipe partially projects from thegroove, which leads to form a plane portion in the refrigerantintroducing pipe. Since this makes it possible to restrict a decrease inthe cross sectional area of the refrigerant introducing pipe caused byplastic deformation, the cooling member manufactured by themanufacturing method for the cooling member is capable of securing apreferable flow of a refrigerant to be introduced into the refrigerantintroducing pipe.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a cooling member and a main portionof a manufacturing device thereof according to Example 1 of the presentinvention;

FIG. 2 (a) is a side view illustrating dimensions of a punch and aheat-transfer member applied to the manufacturing device for a coolingmember according to Example 1 of the present invention;

FIG. 2 (b) is a side view illustrating dimensions of a refrigerantintroducing pipe deformed by the punch;

FIGS. 3 (a) to 3 (c) are respectively a side view illustratingprocedures of a manufacturing method to be carried out using themanufacturing device for the cooling member of the present invention;

FIG. 3 (d) is a cross-sectional view in a width direction in which thecooling member is fractured on A-A lines;

FIG. 4 (a) is a side view showing a process of operation of themanufacturing device for the cooling member according to Example 1 ofthe present invention;

FIG. 4 (b) is a side view showing a process of operation of a firstvariant of the manufacturing device for the cooling member;

FIG. 5 (a) is a cross-sectional view in a width direction showing aprocess of operation of a second variant of the manufacturing device forthe cooling member according to Example 1 of the present invention;

FIG. 5 (b) is a cross-sectional view of a cooling member manufactured bythe device;

FIG. 6 (a) is a cross-sectional view in a width direction showing aprocess of a third variant of the manufacturing device for the coolingmember according to Example 1 of the present invention;

FIG. 6 (b) is a cross-sectional view of a cooling member manufactured bythe device;

FIG. 7 (a) is a plan view of a cooling member according to Example 2 ofthe present invention;

FIG. 7 (b) is a cross-sectional view in a width direction in which thecooling member is fractured on A′-A′ line;

FIG. 8 is a cross-sectional view showing a first variant of the coolingmember according to Example 2 of the present invention;

FIG. 9 is a graph showing changes of thermal resistance ratio caused byan acetic acid salt water spray test to be targeted for the coolingmember shown in FIG. 8;

FIG. 10 is a cross-sectional view showing a second variant of thecooling member according to Example 2 of the present invention;

FIG. 11 is a cross-sectional view showing a third variant of the coolingmember according to Example 2 of the present invention;

FIG. 12 is a cross-sectional view showing a fourth variant of thecooling member according to Example 2 of the present invention;

FIG. 13 is a side view showing a fifth variant of the cooling memberaccording to Example 2 of the present invention;

FIG. 14 (a) is a cross-sectional view in a width direction showing aprocess of a manufacturing method for a cooling member according toembodiments of the present invention;

FIG. 14 (b) is a cross-sectional view of a cooling member manufacturedby the method.

FIG. 15 is a view in which a refrigerant introducing pipe is inaccordance with dimensions of a groove of a heat-transfer member appliedto a method for manufacturing a cooling member according to embodimentsof the present invention;

FIG. 16 is a graph in which a half of a minor axis of a groove in aheat-transfer member applied to the method for manufacturing a coolingmember according to embodiments of the present invention is indicated asa horizontal axis and a calculated value of the circumference of aninner circumferential surface is indicated as a vertical axis;

FIG. 17 is a graph showing a dent ratio of a refrigerant introducingpipe deformed by the method for manufacturing a cooling member accordingto embodiments of the present invention in a horizontal axis and anincrease ratio of pressure loss of refrigerant according to an increasein the dent ratio in a vertical axis;

FIG. 18 (a) is a cross-sectional view showing a fifth variant of aheat-transfer member applicable to the method for manufacturing acooling member according to embodiments of the present invention;

FIG. 18 (b) is a cross-sectional view showing a sixth variant of aheat-transfer member applicable to the method for manufacturing acooling member according to embodiments of the present invention;

FIG. 19 is a perspective view illustrating procedures for a conventionalmethod for manufacturing a cooling member;

FIGS. 20 (a) and 20 (c) are respectively side views illustratingprocedures for a conventional manufacturing method for a cooling member;

FIG. 20 (b) is a cross-sectional view taken on B-B lines;

FIG. 20 (d) is a cross-sectional view taken on C-C lines;

FIG. 21 (a) is a cross-sectional view showing an example of aconventional process for manufacturing a cooling member:

FIG. 21 (b) is a cross-sectional view showing an example of a coolingmember manufactured by the process;

FIG. 22 (a) is a cross-sectional view showing a conventional process formanufacturing a cooling member:

FIGS. 22 (b) to 22 (d) are respectively cross-sectional views of anexample of a cooling member manufactured by the process.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The cooling member, the device and the method for manufacturing thecooling member according to the present invention will now be describedin the following Examples 1 to 3.

Example 1

As shown in FIG. 1, a device 1 for manufacturing a cooling membercomprises: a punch 7 wherein corners 3 are formed in a curved surfaceshape at both ends and a pressing surface 5 is a lower surface of theweb of the punch 7; and a support 13 for supporting a heat-transfermember 9 in such a posture that a groove 11 is arranged at a positionopposite to the pressing surface 5.

The punch 7 is a cuboid in which two corners 3 are respectively locatedadjacent to the pressing surface 5. The wording “in a curbed surfacestate” of the corners 3 herein does not only mean that the surface is aspherical-like state but also means an aspheric surface-like state.Further, the punch 7 is to be attached to a ram of a press machine as amold. Since a press machine is an obvious art, it is omitted in figures.The support 13 is a jig for positioning the heat-transfer 9 on a bed ofthe press machine and may fix the heat-transfer member 9 using bolts orthe like.

FIG. 2 (a) shows a state that the punch 7 moves backward (rise) from theheat-transfer member 9. And FIG. 2 (b) shows a state that the punch 7moves closer to the heat-transfer member 9. As mentioned above, the twocorners 3 of the punch 7 arranged at a position opposite to theheat-transfer member 9 are respectively positioned inwardly of edges 15longitudinally located at both sides of the heat-transfer member 9.Dimension d shows a distance from a boundary between the corners 3 andthe pressing surface 5 to the edges 15. A width x to be pressed whichcorresponds to longitudinal dimensions of the pressing surface 5 is setto be shorter than a full width L. The full width L is a distance wherethe edges 15 of both sides of the heat-transfer member 9 are spaced

Referring to a method for manufacturing a cooling member as below. Asshown in FIG. 3 (a), the punch 7 is moved backward from theheat-transfer member 9 to insert a refrigerant introducing pipe 17 intoa groove 11 and then the punch 7 is moved forward. In this process, asshown in FIG. 3 (b), first, the entire area of the pressing surface 5 ofthe punch 7 contacts the refrigerant introducing pipe 17. Therefrigerant introducing pipe 17 is pressed to the pressing surface 5 byfurther moving the punch 7 forward to be plastically deformed into aflattened shape, the corners 3 gradually come in contact with a surfaceof the refrigerant introducing pipe 17. A force with which the corners 3press the refrigerant introducing pipe 17 is dispersed in a longitudinaldirection outwardly beyond the corners 3, resulting in no scratch on thesurface of the refrigerant introducing pipe 17 by being excessivelypressed by the corners 3. As mentioned above, it is possible to securereliability and physical strength of the refrigerant introducing pipe 17by keeping the surface of the refrigerant introducing pipe 17 smooth.

As shown in FIG. 2 (b), operation for moving the punch 7 forward isstopped when a deformation quantity p of the refrigerant introducingpipe 17 reaches a desired size to move the punch 7 backward to theposition shown in FIG. 2 (a). The refrigerant introducing pipe 17 isclosely fitted with the inner surface of the groove 11 in the process sofar. And as shown in FIG. 3 (c), curbed surfaces of curvature radius Rsubstantially identical to the corners 3 of the punch 7 are formed inthe refrigerant introducing pipe 17. Further, no unnecessary bendingforce is applied to the refrigerant introducing pipe 17 projecting fromthe edges 15 because a reaction force for plastically deforming theaforementioned refrigerant introducing pipe 17 is completely receivedbetween the corners 3 of the punch 7 and the edges 15 of theheat-transfer member 9. Accordingly, it is possible to assemble acooling member 19 which is accurate in dimension and direction of therefrigerant introducing pipe 17 projecting from the edges 15.

In the cooling member 19, a region 23 to be pressed is formed in therefrigerant introducing pipe 17 by the shrinkage of the refrigerantintroducing pipe 17 in a direction where the refrigerant introducingpipe 17 is pressed to the punch 7 of a press machine. Moreover, in therefrigerant introducing pipe 17, curbed surface portions 25 in the shapeof gradually shrinking in a direction where the refrigerant introducingpipe 17 are pressed to the press machine with a move to the region 23 tobe pressed from the edges 15 of the heat-transfer member 9. Graduallyshrinking means herein that the refrigerant introducing pipe 17 ismostly plastically deformed into the shape of a curbed surface of thecurvature radius R in accordance with the corners 3 of the punch 7.

The curvature radius R is preferably greater than a thickness t of therefrigerant introducing pipe 17 from a viewpoint of avoiding theconcentration of stress on a portion where the refrigerant introducingpipe 17 has been deformed. Further, when the curvature radius R isgreater than a diameter φ of the refrigerant introducing pipe 17, thedeformation quantity of the refrigerant introducing pipe 17 runs shortbetween the corners 3 of the punch 7 and the edges 15 of theheat-transfer member 9. As a result, a contact force between the innersurface of the groove 11 and the refrigerant introducing pipe 17 becomesweaker, so that heat-transfer performance therebetween is lost. It is,therefore, preferable to set in such a manner that the curvature radiusR of the corners 3 is t<R<φ.

Since the corners 3 of the punch 7 get closer to the edges 15 of theheat-transfer member 9 so as to set the dimension d small, resulting ina stronger tendency to apply a bending force based on the reaction forceof the aforementioned plastic deformation to the refrigerant introducingpipe 17, the dimension d is preferably set greater than the deformationquantity p of the refrigerant introducing pipe 17. Since the width x tobe pressed of the pressing surface 5 is restricted when the dimension dis set to be twice as great as the diameter φ of the refrigerantintroducing pipe 17, heat-transfer performance between the inner surfaceof the groove 11 and the refrigerant introducing pipe 17 is lost.Accordingly, the dimension d is preferably set in such a manner thatp<d<2φ.

As FIG. 3 (d) shows, when the aforementioned conditions that p<d<2φ aresatisfied, an arc-like clearance 21 remains between the inner surface ofthe groove 11 near the edge 15 and the refrigerant introducing pipe 17in the stage that the cooling member 19 is assembled. Even when anexternal force is applied to the refrigerant introducing pipe 17 in abending direction, it is possible to secure the physical strength of therefrigerant introducing pipe 17 and reduce time and costs for performingR processing on respective heat-transfer members like conventional onesbecause it is possible to prevent the concentration of the stress nearthe boundary between the refrigerant introducing pipe 17 and the edges15.

In the case where work for coating the refrigerant introducing pipe 17shown in FIG. 3 (c) with a coating material, the coating material isintroduced to the whole circumference of the refrigerant introducingpipe 17 along the clearance 21 by making the boundary between therefrigerant introducing pipe 17 and the edges 15 indicating as referencenumeral 23 lightly in contact with the coating material (capillarity).Additionally, it is possible to easily perform this work from a surfaceside of the cooling member 19, so that it is possible to efficientlycoat a desired portion in the cooling member 19 with the coatingmaterial.

And the heat-transfer member 9 may be directly positioned on a bed ofthe press machine so that the bed can play a role of a support 13. Forinstance, it is not essential that one punch 7 has two corners 3 and onepunch or a plurality of punches having one corner may be attached to aram of the press machine. The shape of the heat-transfer member 9 is notlimited to a rectangular plate but may be disk-shaped.

As shown in FIG. 4 (a), there is a possibility that a reaction force ofplastically deforming the refrigerant introducing pipe 17 with a pressmachine may cause an upward warping on the refrigerant introducing pipe17. Therefore, as shown in FIG. 4 (b), back-up portions 27 extendingfrom both ends in a direction along the refrigerant introducing pipe 17are provided on the punch 7 to hit the back-up portions 27 against therefrigerant introducing pipe 17 upwardly depending on the material ofthe refrigerant introducing pipe 17 and a speed of moving the punch 7forward. This restricts the warping of the refrigerant introducing pipe17 and makes it possible to assemble the cooling member 19 that isaccurate in dimension and direction of the refrigerant introducing pipe17 projecting from the edges 15.

Furthermore, while explanation has been given as described aboveprovided that the pressing surface 5 of the punch 7 is in the flatshape, as shown in FIG. 5 (a), the pressing surface 5 may be in a convexshape projecting against the groove 11. In this case, the cross sectionof the region 23 to be pressed in the refrigerant introducing pipe 17turns into a concave shape as shown in FIG. 5 (b) when pressing thepressing surface 5 to the refrigerant introducing pipe 17 inserted intothe groove 11. Alternatively, as shown in FIG. 6 (a), the pressingsurface 5 may be concave-shaped against the groove 11. In this case, thecross section of the region 23 to be pressed turns into a convex shapeas shown in FIG. 6 (b) when pressing the pressing surface 5 to therefrigerant introducing pipe 17.

Example 2

Same names will be subsequently used for elements already mentioned inExample 1 regardless of embodiments shown in the following drawings orwhether or not shown in figures.

As shown in FIG. 7 (a), in a cooling member 101, a refrigerantintroducing pipe 107 is pressed into grooves 105 of a heat-transfermember 103 and a surface 111 of the heat-transfer member 103 and therefrigerant introducing pipe 107 are covered with covering materials113. As shown in FIG. 7 (b), a heat-conducting member 117 composed of analuminum plate is attached to electric parts 115 to connect theheat-transfer member 103 to the electric parts 115 through theheat-conducting member 117. However, the heat-conducting member 117 maybe omitted and the heat-transfer member 103 may be directly connected tothe electric parts 115.

The heat-transfer member 103 is an aluminum plate and openings of thegrooves 105 are opened on the surface 111 of the heat-transfer member103. The covering materials 113 are coating materials applied to dottedregions of the refrigerant introducing pipe 107 in the figure. Suchregions are not limited at all, but it is enough that at least thecoating materials may be applied to joints 119 between the heat-transfermember 103 and the refrigerant introducing pipe 107. Additionally, filmsor adhesive tapes to be adhered to the aforementioned regions may beapplied as the covering materials 113. Alternatively, plate materials121 shown in FIG. 8 may be applied.

In the cooling member 101, the joints 119 between the heat-transfermember 103 and the refrigerant introducing pipe 107 are blocked from theperipheral atmosphere by the covering materials 113. Thus, it ispossible to prevent moisture from entering the joints 119 even when theheat-transfer member 103 and the refrigerant introducing pipe 107 buildup condensation. And even when the heat-transfer member 103 and therefrigerant introducing pipe 107 contact poisonous gas or are under theenvironment in which salt is splashed, it is possible to preventpoisonous gas or salt from entering the joints 119 using the coveringmaterials 113. This makes it possible to prevent the heat-transfermember 103 and the refrigerant introducing pipe 107 from corrosion.

In addition, the cooling member 101 is capable of securing preferableheat transfer between the heat-transfer member 103 and the refrigerantintroducing pipe 107 as below and allowing performance of the electricparts 115 to properly exert.

That is, the cooling member 101 shown in FIG. 7 (a) is used as a sampleof an example and a comparative sample in which covering materials areremoved from the similar cooling member is prepared. Acetic acid saltwater is then sprayed toward respective joints 119 of respective samplesin the example and the comparative sample to measure thermal resistanceratio of the heat-transfer member 103 and the refrigerant introducingpipe 107 every time a certain time passes. This result is indicated in agraph in FIG. 9 in which spray time for spraying acetic acid salt wateris indicated as a horizontal axis and thermal resistance ratio isindicated as a vertical axis. While a solid line S in FIG. 9 indicatesthat the thermal resistance ratio has little increased in the sample ofthe example, a dotted line C indicates that the thermal resistance ratioof the comparative sample has increased as a spray time passes.

It is possible to achieve effects of the cooling member 101 as describedabove whether or not the covering materials are films, adhesive tapes,coating materials or the plate material 121. Particularly, in the casewhere coating materials are selected as the covering materials 113, itis possible to easily achieve the aforementioned effects by simplyapplying the coating materials to the surface 111 of the heat-transfermember 103 and the refrigerant introducing pipe 107 quickly.

As shown in FIG. 10, a cooling member 123 is similar to theaforementioned cooling member 101 except that a cover 125 for coveringthe heat-transfer member 103 and the refrigerant introducing pipe 107 isapplied as a covering material. In the cover 125, the heat-transfermember 103 is buried inside a channel portion 124 to arrange a pair offlanges 126 extending from both sides of the channel portion 124 at aposition opposite to the heat-conducting member 117. The flanges 126 ofthe cover 125 may be fixed to the heat-conducting member 117 with anadhesive or may be fastened with screws or the like. Further, it ispreferable that the heat-conducting member 117 and the pair of flanges126 are airtightly joined to each other and a sealing material mayintervene therebetween and the like.

Since it is easy to remove the cover 125 from the heat-transfer member103 as a merit of the cooling member 123, it is possible to efficientlyseparate the cover 125 and the heat-transfer member 103 to performrecycling. Furthermore, the material of the cover 125 may be a metal ora synthetic resin and thus a substance having a physical strength higherthan the coating material may be applied. The cover 125 has, therefore,a merit of being insusceptible to damage, even when receiving anexternal force or an impact, and not carelessly dropping out of theheat-transfer member 103.

As shown in FIG. 11, the heat-conducting member 117 is utilized as acovering material in a cooling member 127, so that the number of partsis few and the manufacturing costs are less expensive because neitherthe aforementioned coating materials nor the cover is needed. In thiscase, electric parts 115 are mounted on one surface 129 of theheat-conducting member 117 and the surface 111 of the heat-transfermember 103 and the refrigerant introducing pipe 107 are closely fittedwith other surface 131 of the heat-conducting member 117.

As shown in FIG. 12, the heat-transfer member 103 and the refrigerantintroducing pipe 107 may be housed in the cover 125 in the state thatthe surface 111 of the heat-transfer member 103 and the refrigerantintroducing pipe 107 are closely fitted with the other surface 131 ofthe heat-conducting member 117. As mentioned above, the clearance 21shown in FIG. 3 (d) remains in the cooling member. Sealing materials 132shown in FIG. 13 may be inserted into such a clearance to prevent waterand dirt or the like from entering between the heat-transfer member 103and the refrigerant introducing pipe 107.

Example 3

Embodiments of a cooling member and a method for manufacturing the sameaccording to the present invention will now be described. FIG. 14 (a)shows a heat-transfer member 207 in which an opening 203 of a groove 201is opened to a surface 205, a punch 211 having a flat pressing surface209 arranged at a position opposite to the groove 201, and a refrigerantintroducing pipe 213 inserted into the groove 201. Curved surface-shapedcorners are longitudinally formed at ends of the punch 211 in the samemanner as Example 1.

As shown in FIG. 15, a center of curvature O of an inner circumferentialsurface 217 of the groove 201 is positioned inward the opening 203. Twocorner portions 219 and 221 are the locations where the innercircumferential surface 217 warping in the shape of an ellipse isadjacent to an inner side 223 of the opening 203. The circumference ofthe inner circumferential surface 217 means herein the length of theinner circumferential surface 217 from the corner portion 219 to thecorner portion 221. However, in Example 3, a thickness E from the cornerportion 219 to the surface 205 and a thickness E from the corner portion221 to the surface 205 are added. Accordingly, when the circumference ofthe inner circumferential surface 217 is L, A+L+2E<πG and the groove 201satisfies with the conditions that the length (A+L) that thecircumference of the inner circumferential surface 217 is added to thewidth A of the opening 203 is shorter than an outer circumference (πG)of the refrigerant introducing pipe 213.

TABLE 1 Symbol Dimensions [mm] Designation A 9.7 ± 0.1 Width of openingB 10.7 ± 0.1  Major axis C 3.95 Half of minor axis D 5.61 Height ofintersection point E 0.44 Thickness F 5.95 ± 0.1  Depth G 5.92 ± 0.08Diameter

Table 1 shows dimensions of A to G. All of the unit of dimensionsmentioned below is [mm]. Referring now to the procedures to calculatethe dimensions of A to G using a case where the diameter of therefrigerant introducing pipe 213 includes a margin of errors ±0.08 whenthe diameter is 9.52 as an example. First, it is set that A=9.7±0.1 insuch a manner that a width A of the opening 203 may be not smaller thanthe maximum value of 9.60 of the diameter of the refrigerant introducingpipe 213. The maximum value Amax of the width A in the opening 203=9.8.The minimum value Bmin=10.6 is calculated based on the followingequation so that an over hang quantity, in which the difference betweenthe maximum value Amax and the minimum value Bmin of a full width B ofthe inner circumferential surface 217 that is a major axis of an ellipseis divided by 2, may be at least 0.4 (about 4% of A). When the margin oferrors at the time of the formation of the groove 201 in theheat-transfer member 207 is estimated to be ±0.1, the value of B may bedetermined at 10.7±0.1.

$\begin{matrix}{\frac{{B\; \min} - {A\; \max}}{2} = {0.4\mspace{14mu}\lbrack{mm}\rbrack}} & \left\lbrack {{Equation}\mspace{14mu} 1} \right\rbrack\end{matrix}$

Subsequently, assuming that a thickness E=0.44, a calculated value ofthe circumference of the inner circumferential surface 217 at the timewhen the minor axis of an ellipse in contact with both corner portions219 and 221 is obtained. FIG. 16 is a graph in which a half of a minoraxis corresponding to a half of a minor axis of an ellipse is indicatedas a horizontal axis and a calculated value of the circumference of theinner circumferential surface 217 is indicated as a vertical axis. Sincethe minimum value of the outer circumstance (πG) of the refrigerantintroducing pipe 213 is approximately 29.7, conditions in which thecircumference of the inner circumferential surface 217 is shorter thanthe minimum value are that the half of the minor axis of the ellipse isnot more than the value divided by a broken line in FIG. 16. Forexample, when πG<29, c<4.

The method for manufacturing a cooling member 215 is as below. Referringnow to FIG. 14 (a) and FIG. 14 (b) unless otherwise limited. First, therefrigerant introducing pipe 213 inserted into the groove 201 of theheat-transfer member 207 is pressed into the groove 201 with the punch211 so that the refrigerant introducing pipe 213 to be plasticallydeformed may be closely fitted with the inner circumferential surface217 of the groove 201. At this point, the refrigerant introducing pipe213 partially projects from the opening 203 of the groove 201. This isbecause a portion of the refrigerant introducing pipe 213 projects fromthe surface 205 of the heat-transfer member 207 by the length to whichthe circumference of the inner circumferential surface 217 is added tois shorter than the outer circumference of the refrigerant introducingpipe 213. Additionally, the center of curvature O of the groove 201 islocated inwardly of the opening 203 in the heat-transfer member 207.Accordingly, as mentioned above, at the point when the refrigerantintroducing pipe 213 is closely fitted with the inner circumferentialsurface 217 of the groove 201, the width of the refrigerant introducingpipe 213 becomes greater than the opening 203, which leads to restrictthe separation of the refrigerant introducing pipe 213 from theheat-transfer member 207. This completes the join between theheat-transfer member 207 and the refrigerant introducing pipe 213.

Therefore, according to the method described above, there is nopossibility of a clearance remaining between the heat-transfer member207 and the refrigerant introducing pipe 213 at the point when theheat-transfer member 207 is joined to the refrigerant introducing pipe213 in a state that the refrigerant introducing pipe 213 projects fromthe surface 205 of the heat-transfer member 207, even when andimensional error is respectively included in the outer circumference ofthe refrigerant introducing pipe 213 and the circumference of the innercircumferential surface 217 in the groove 201. This enables the coolingmember 215 to materialize preferable heat transfer from theheat-transfer member 207 to a curved portion 225 of the refrigerantintroducing pipe 213. The curbed portion 225 is a portion where therefrigerant introducing pipe 213 has been plastically deformed into anellipse that is in the same shape as the inner circumferential surface217 of the groove 201 by being fitted with the inner circumferentialsurface 217. Further, the cross section of the inner circumferentialsurface 217 is an ellipse in which the direction of the major axis isconformed to the width direction of the opening 203, so that it ispossible to firmly hold the refrigerant introducing pipe 213 on theheat-transfer member 207 relative to an external force in a deviationdirection to be applied to the refrigerant introducing pipe 213.

Furthermore, according to the method described above, it is possible toprevent the refrigerant introducing pipe 213 from bending by force bysetting a force to press the refrigerant introducing pipe 213 with thepunch 211 so that the refrigerant introducing pipe 213 may project fromthe surface 205 until the refrigerant introducing pipe 213 partiallyprojects from the groove 201, which leads to form a plane portion 227 onthe refrigerant introducing pipe 213. The plane portion 227 is a portionwhere the refrigerant introducing pipe 213 has been plastically deformedinto a flat shape which is in the same shape as the pressing surface 209of the punch 211.

FIG. 17 is a graph in which a horizontal axis represents a dent ratioobtained by dividing a dent amount Δt of the plane portion 227 by themajor axis B (full width of the inner circumferential surface 217) and avertical axis represents a ratio of increasing pressure loss in arefrigerant flowing in the refrigerant introducing pipe 213 as the dentratio increases as an increase ratio of pressure loss. It will beunderstood from FIG. 17, it is necessary to limit the dent ratio to 0.3or smaller to make the increase ratio of pressure loss to 3 or smaller.To materialize this, a force of the punch 211 to press the refrigerantintroducing pipe 213 is so adjusted that a height t of the plane portion227 projecting from the surface 205 of the heat-transfer member 207 maybe smaller than the thickness of the refrigerant introducing pipe 213.

The dimensional difference between the major axis of the ellipse and thewidth of the opening 203 is greater than the case in which the crosssection of the inner circumferential surface 217 is in the shape of aconventional arc because the direction of the major axis of theaforementioned ellipse coincides with the width direction of the opening203 in the cooling member 215. Accordingly, that is advantageous toincrease an over hang quantity in the stage of forming the groove 201 inthe cooling member 215, resulting in reinforcement of the joiningbetween the heat-transfer member 207 and the refrigerant introducingpipe 213. Additionally, it is possible to improve the physical strengthof the opening 203 in the heat-transfer member 207 by setting thethickness E at 0.44 in the aforementioned example.

In order to recycle the cooling member 215, it is necessary to separatethe refrigerant introducing pipe 213 in which the curbed portion 225 andthe plane portion 227 are formed to sort out the refrigerant introducingpipe 213 and the heat-transfer member 207. In this case, it is possibleto return the cross section of the refrigerant introducing pipe 213 to acircle to easily remove the refrigerant introducing pipe 213 from theopening 203 of the groove 201 by supplying inside the refrigerantintroducing pipe 213 with compressed air so as to expand the refrigerantintroducing pipe 213.

It is to be understood that the present invention may also be carriedout in aspects to which various improvements, modifications orvariations are added based on knowledge of a skilled person in the artwithout departing from the spirit and scope of the invention. Typically,the cross section of the inner circumferential surface 217 is notlimited to an ellipse, but may be in the shape of a parabola havingconformed to the direction of a geometric central axis to the widthdirection of the opening 203. As shown in FIG. 18 (a), the cross sectionof the inner circumferential surface 217 may be in an oval shape inwhich the major axis coincides with the width direction of the opening203. Alternatively, the inner circumferential surface 217 of the groove201 may be in the shape that an arc portion 319 and a linear bottomsurface 321 are combined together. As shown in FIG. 18 (b), the innercircumferential surface 217 has two or more centers of curvature O.

Even when an external force in a deviation direction is applied to therefrigerant introducing pipe 213 being closely fitted with the innercircumferential surface 217 of the groove 201, the aforementionedcooling member having the heat-transfer member 207 is capable ofpreventing the refrigerant introducing pipe 213 from rotating relativeto the heat-transfer member 207 without heavily depending on africtional force between the heat-transfer member 207 and the innercircumferential surface 217.

INDUSTRIAL APPLICABILITY

The present invention is a useful technology to manufacture a coolingmember for cooling electric parts to produce heat, such as power modulesor the like.

DESCRIPTION OF THE REFERENCE NUMERALS

-   1: device for manufacturing a cooling member, 3: corner, 5: pressing    surface, 7: punch, 9: heat-transfer member, 11: groove, 13: support,    15: edge, 17: refrigerant introducing pipe, 19: cooling member, 23:    region to be pressed, 25: curbed surface portion, 27: back-up    portion-   101, 123, 127: cooling member, 103: heat-transfer member, 105:    groove, 107: refrigerant introducing pipe, 111: surface 113:    covering material, 115: electric parts, 117: heat-conducting member,    125: cover, 129: one surface, 131: other surface, 132: sealing    member-   201: groove, 203: opening, 205: surface, 207: heat-transfer member,    211: punch, 213: refrigerant introducing pipe, 215: cooling member,    217: inner circumferential surface, 225: curved portion, 227: plane    portion

1. A method for manufacturing a cooling member including a heat-transfermember having a groove and at least one edge which is a longitudinallimit of the groove and a refrigerant introducing pipe disposed in thegroove, the method comprising: preparing a punch having at least onecorner formed in a curved surface shape at one end or more thereof, anda pressing surface adjacent to the corner to arrange the pressingsurface of the punch at a position opposite to the groove; positioningthe corner of the punch longitudinally inwardly of the edge of theheat-transfer member; and moving the punch closer to the groove to pressthe refrigerant introducing pipe into the groove with the pressingsurface.
 2. A cooling member comprising: a heat-transfer member having agroove and at least one edge which is a longitudinal limit of thegroove; and a refrigerant introducing pipe pressed into the groove witha press machine, the refrigerant introducing pipe having a pressedregion, which shrinks by being pressed with the press machine,positioned inwardly of the edge of the heat-transfer member, and atleast one curbed surface portion in a gradually shrinking shape in adirection from where the refrigerant introducing pipe is pressed by thepress machine with a move from the edge of the heat-transfer member tothe pressed region.
 3. A device for manufacturing a cooling memberincluding a heat-transfer member having a groove and at least one edgewhich is a longitudinal limit of the groove and a refrigerantintroducing pipe pressed into the groove, the device comprising: a punchhaving at least one corner formed in a curved surface shape at one endor more thereof, and a pressing surface adjacent to the at least onecorner; and a support arranged and configured to support theheat-transfer member such that the groove is arranged at a positionopposite to the pressing surface, the corner being arranged andconfigured to contact the refrigerant introducing pipe longitudinallyinwardly of the edge when the punch presses the refrigerant introducingpipe into the groove with the pressing surface.
 4. The device accordingto claim 3, wherein the punch has at least one back-up portion extendingoutwardly of the edge of the heat-transfer member, and the back-upportion hits against the refrigerant introducing pipe when the corner ofthe punch comes in contact with the refrigerant introducing pipe.
 5. Thecooling member according to claim 2, wherein the heat-transfer memberhas an opened surface where the groove is located and surfaces of theheat-transfer member and the refrigerant introducing pipe are coatedwith a covering material.
 6. The cooling member according to claim 5,wherein the covering material includes a coating material applied to theheat-transfer member and the refrigerant introducing pipe.
 7. Thecooling member according to claim 5, wherein the covering materialincludes a cover that covers for covering the heat-transfer member. 8.The cooling member according to claim 5, wherein electric parts aremounted on one surface of a heat-conducting member, which is arrangedand configured to make the heat-transfer member and the refrigerantintroducing pipe closely fitted with each other on another surface ofthe heat conducting member.
 9. The cooling member according to claim 5,wherein a sealing member is arranged and configured to intervene betweenthe groove of the heat-transfer member and the refrigerant introducingpipe, and the sealing member is provided longitudinally outwardly of atleast one end of the pressed region.
 10. The cooling member according toclaim 2, wherein the groove has an inner circumferential surface in anoval shape to determine a center inwardly of an opening opened to asurface of the heat-transfer member and conforming a direction of amajor axis to a width direction of the opening, and the refrigerantintroducing pipe includes a curved portion closely fitted with the innercircumferential surface, and a plane portion blocking the opening. 11.The cooling member according to claim 10, wherein the oval is anellipse.
 12. A method for manufacturing a cooling member comprising thesteps of: preparing a punch having at least one corner formed in acurved surface shape at one end or more thereof, and a pressing surfaceadjacent to the at least one corner; preparing a heat-transfer memberhaving a groove with an oval shaped inner circumferential surface todetermine a center inwardly of an opening of the groove and conforming adirection of a major axis to a width direction of the opening; insertinga refrigerant introducing pipe into the groove; arranging a pressingsurface of the punch at a position opposite to the groove; positioningthe corner of the punch inwardly of at least one longitudinal edge ofthe heat-transfer member; moving the punch closer to the groove to pressthe refrigerant introducing pipe into the groove with the pressingsurface; and plastically deforming the refrigerant introducing pipe soas to be closely fitted with the inner circumferential surface of thegroove.
 13. The method according to claim 12, wherein the oval is anellipse.
 14. The cooling member according to claim 2, wherein a centerof curvature of an inner circumferential surface in the groove isdisposed inwardly of an opening of the groove, a length obtained byadding the circumference of the inner circumferential surface to thewidth of the opening is shorter than an outer circumference of therefrigerant introducing pipe, and further wherein the refrigerantintroducing pipe includes a curved portion closely fitted with the innercircumferential surface, and a plane portion blocking the opening andprojecting from a surface of the heat-transfer member.
 15. A method formanufacturing a cooling member comprising the steps of: preparing apunch having at least one corner formed in a curved surface shape at oneend or more thereof, and a pressing surface adjacent to the at least onecorner; preparing a heat-transfer member having a groove with a centerof curvature of an inner circumferential surface thereof being disposedinwardly of an opening of the groove and a length obtained by adding thecircumference of the inner circumferential surface to the width of theopening is shorter than an outer circumference of a refrigerantintroducing pipe; inserting the refrigerant introducing pipe into thegroove; arranging a pressing surface of the punch at a position oppositeto the groove; positioning the corner of the punch inwardly of at leastone longitudinal edge of the heat-transfer member; moving the punchcloser to the groove to press the refrigerant introducing pipe into thegroove with the pressing surface; and plastically deforming therefrigerant introducing pipe so as to be closely fitted with the innercircumferential surface of the groove.
 16. The cooling member accordingto claim 6, wherein a sealing member is arranged and configured tointervene between the groove of the heat-transfer member and therefrigerant introducing pipe, and the sealing member is providedlongitudinally outwardly of at least one end of the pressed region. 17.The cooling member according to claim 7, wherein a sealing member isarranged and configured to intervene between the groove of theheat-transfer member and the refrigerant introducing pipe, and thesealing member is provided longitudinally outwardly of at least one endof the pressed region.
 18. The cooling member according to claim 8,wherein a sealing member is arranged and configured to intervene betweenthe groove of the heat-transfer member and the refrigerant introducingpipe, and the sealing member is provided longitudinally outwardly of atleast one end of the pressed region.